The cleaning of moulding tools at a brake linings and clutches production company is carried out in a traditional way in a caustic soda bath, a method that is not very efficient, and also generates very heavy liquid discharges. Switching to ultrasonic cleaning optimizes the cleaning operation, reduce the cleaning time, and provide better work conditions for the workers.
Production stops in a metal packaging manufacturing facility are due to interuptions in the supply of pallets from the store to the production site. Reviewing the procedures for transfer of material, having the raw material supply within the priority of forklift drivers, and assuring strategic stock of raw material within the production hall eliminates those interuptions, providing production gains.
Mapping the cause of high warranty claims in a battery manufacturing company revealed that major cause is loose welding of battery terminals. Setting a quality control procedure, training the staff, and maintaining the welding machines and tips reduces those claims, and consequent market returns.
Using rollers with carbide inserts rather than standard steel rollers in the pipe profiling lines reduces the wear of pipes, eliminating material loss, and increases the productivity and product quality.
An automotive cables manufacturing company had four large motors that are close to the end of their service life, and are direct current motors. Replacing those motors with asynchronous AC motors increases the motor efficiency, and reduces its running cost. This action also saves on electricity consumption of the company.
A brake linings and clutches production company has two impregnation booths. Thermal energy is provided by steam in the one booth and by electrical resistance in the other. As the electric resistance has higher efficiency, and maintains better control over temperature within the booth, the steam operated booth is converted to operate by electrical resistance.
Stoppage of wire drawing machines generates losses in raw material. Investigating the reasons for these stoppages in an automotive cable company revealed that lack of machine maintenance together with the low quality of used copper are main reasons. adopting preventive maintenance program, and contacting the copper suppliers to provide high quality material reduces those stoppages, and consequently saves on material and increases productivity.
End of line rejects are high in a pipe manufacturing company. Those rejects are due to the lack of technical skills for the workers, and rejects occuring due to misadjustment of equipment during change of set. Adopting a lean manufacturing methodology or KAIZEN technique together with a training campaign for labor and employees significantly reduces those rejects.